Professional Documents
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ROTOPLAT LP 308FR-508PDS-708PVS
ROTOPLAT TP 108-308-508-708
ENG
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ENG 2
Index
1. GENERAL INFORMATION ................................................................................................................................. 6
1.1. PURPOSE OF THE MANUAL ............................................................................................................................. 6
1.2. MANUFACTURER AND MACHINE IDENTIFICATION ....................................................................................... 7
1.3. TERMS AND DEFINITIONS ................................................................................................................................ 8
1.3.1. PICTOGRAMS INDICATING DANGER ....................................................................................................... 9
1.3.2. PICTOGRAMS INDICATING PROHIBITION ............................................................................................. 10
1.3.3. PICTOGRAMS INDICATING OBLIGATION ............................................................................................... 11
1.4. HOW TO REQUEST ASSISTANCE .................................................................................................................. 12
1.5. ATTACHED DOCUMENTATION ....................................................................................................................... 12
1.6. HOW TO READ THE INSTRUCTIONS FOR USE ............................................................................................ 12
2. SAFETY INFORMATION................................................................................................................................... 13
2.1. GENERAL SAFETY WARNINGS ...................................................................................................................... 13
2.2. SAFETY WARNINGS FOR HANDLING AND INSTALLATION ......................................................................... 14
2.3. SAFETY WARNINGS FOR USE AND OPERATION ........................................................................................ 15
2.4. SAFETY WARNINGS RELATED TO MISUSE .................................................................................................. 16
2.4.1. REASONABLY FORESEEABLE MISUSE ................................................................................................. 16
2.4.2. EMPLOYER OBLIGATIONS ...................................................................................................................... 16
2.5. SAFETY WARNINGS ON RESIDUAL RISKS ................................................................................................... 17
2.6. SAFETY WARNINGS FOR ADJUSTMENTS AND MAINTENANCE ................................................................ 20
2.7. SAFETY WARNING FOR THE ELECTRICAL EQUIPMENT ............................................................................ 20
2.8. INFORMATION AND SAFETY SIGNS .............................................................................................................. 21
2.9. PERIMETER AREAS ......................................................................................................................................... 23
3. TECHNICAL INFORMATION ............................................................................................................................ 24
3.1. MACHINE GENERAL DESCRIPTION ............................................................................................................... 24
3.1.1. MACHINE MODELS DESCRIPTION ......................................................................................................... 26
3.2. DESCRIPTION OF THE OPERATION CYCLE ................................................................................................. 27
3.3. SAFETY DEVICE DESCRIPTION ..................................................................................................................... 28
3.4. DESCRIPTION OF ELECTRICAL DEVICES .................................................................................................... 31
3.4.1. REMOTE CONTROL SOFTWARE ............................................................................................................ 33
3.5. DESCRIPTION OF PNEUMATIC DEVICES ..................................................................................................... 34
3.6. DESCRIPTION OF ACCESSORIES ON REQUEST ......................................................................................... 35
3.7. "ROTOPLAT 308-508-708" TECHNICAL DATA ................................................................................................ 39
3.7.1. MACHINE AND PALLET DIMENSIONS .................................................................................................... 39
3.7.2. MACHINE TECHNICAL FEATURES .......................................................................................................... 40
3.7.3. PRESSER TECHNICAL FEATURES ......................................................................................................... 40
3.7.4. PNEUMATIC CREASING HEAD TECHNICAL FEATURES ...................................................................... 40
3.7.5. SPOOL FEATURES ................................................................................................................................... 41
3.8. "ROTOPLAT LP 308 - 508 - 708" TECHNICAL DATA ...................................................................................... 42
3.8.1. MACHINE AND PALLET DIMENSIONS .................................................................................................... 42
3.8.2. MACHINE TECHNICAL FEATURES .......................................................................................................... 43
3.8.3. PRESSER TECHNICAL FEATURES ......................................................................................................... 43
3.8.4. PNEUMATIC CREASING HEAD TECHNICAL FEATURES ...................................................................... 43
3.8.5. SPOOL FEATURES ................................................................................................................................... 44
3.9. “ROTOPLAT TP3 308-508-708" TECHNICAL DATA ........................................................................................ 45
3.9.1. MACHINE AND PALLET DIMENSIONS .................................................................................................... 45
3.9.2. MACHINE TECHNICAL FEATURES .......................................................................................................... 46
3.9.3. PRESSER TECHNICAL FEATURES ......................................................................................................... 46
3.9.4. PNEUMATIC CREASING HEAD TECHNICAL FEATURES ...................................................................... 46
3.9.5. SPOOL FEATURES ................................................................................................................................... 47
3.10. NOISE LEVEL ................................................................................................................................................ 48
3.11. INSTALLATION ENVIRONMENT CHARACTERISTICS .............................................................................. 48
4. INFORMATION ON HANDLING AND INSTALLATION ...................................................................................... 49
4.1. RECOMMENDATIONS FOR HANDLING AND LOADING................................................................................ 49
4.2. PACKING AND UNPACKING ............................................................................................................................ 49
4.3. TRANSPORT AND HANDLING ......................................................................................................................... 51
4.4. HANDLING AND LIFTING ................................................................................................................................. 52
4.5. INSTALLATION OF THE MACHINE .................................................................................................................. 53
3 Index ENG
4.5.1. ELECTRIC BOX ASSEMBLY ..................................................................................................................... 54
4.5.2. SLIDE SHAFT ASSEMBLY ........................................................................................................................ 55
4.5.3. SLIDE SHAFT ASSEMBLY ........................................................................................................................ 56
4.5.4. LOADING/UNLOADING RAMP ASSEMBLY ............................................................................................. 57
4.5.4.1. LOADING DIRECTION MODIFICATION .......................................................................................... 58
4.5.5. PNEUMATIC PRESSER ASSEMBLY (OPTIONAL) .................................................................................. 62
4.5.6. “BUBBLE WRAP” KIT ASSEMBLY (OPTIONAL) ....................................................................................... 63
4.5.7. MECHANICAL PRESSER ASSEMBLY (OPTIONAL) ................................................................................ 64
4.6. MACHINE FIXING .............................................................................................................................................. 65
4.7. MACHINE UNDERGROUND INSTALLATION .................................................................................................. 66
4.8. RECOMMENDATIONS FOR CONNECTIONS ................................................................................................. 66
4.9. PNEUMATIC CONNECTION ............................................................................................................................. 66
4.10. ELECTRICAL CONNECTION........................................................................................................................ 67
5. INFORMATION ON ADJUSTMENTS ................................................................................................................ 68
5.1. RECOMMENDATIONS FOR ADJUSTMENTS ................................................................................................. 68
5.2. ADJUSTING THE “CARRIAGES” ...................................................................................................................... 69
5.2.1. SPOOL CARRIAGES OF "PDS" TYPE (PRE-STRETCH GEAR REPLACEMENT) ................................. 69
5.2.2. SPOOL CARRIAGES OF "FR for mesh" TYPE ......................................................................................... 71
5.3. SPOOL CARRIAGE LIFTING CHAIN ADJUSTMENT ....................................................................................... 72
5.4. ROTARY TABLE CHAIN ADJUSTMENT .......................................................................................................... 72
5.5. “TP3” TABLE ROTATION CHAIN ADJUSTMENT ............................................................................................. 73
5.6. ADJUSTING ROTARY TABLE GEAR WHEELS ............................................................................................... 74
5.7. ADJUSTING THE TABLE GUIDE WHEELS ..................................................................................................... 75
5.8. “BUBBLE WRAP” SPOOL BRAKING ADJUSTMENT ....................................................................................... 75
6. INFORMATION ABOUT THE USE .................................................................................................................... 76
6.1. RECOMMENDATIONS FOR OPERATION AND USE ...................................................................................... 76
6.2. DESCRIPTION OF THE CONTROLS ............................................................................................................... 77
6.3. DESCRIPTION OF USER INTERFACE ............................................................................................................ 78
6.3.1. NUMERICAL AND ALPHANUMERICAL KEYBOARD ............................................................................... 81
6.3.2. PROGRAMMING WINDOW ....................................................................................................................... 82
6.4. “HOME” PAGE ................................................................................................................................................... 83
6.5. “MANUAL HANDLING” PAGE ........................................................................................................................... 85
6.5.1. MANUAL REINFORCEMENT FUNCTION ................................................................................................. 86
6.6. “RECIPES” PAGE .............................................................................................................................................. 87
6.7. “WRAPPING CYCLE” PAGE ............................................................................................................................. 88
6.8. “GENERAL PARAMETERS” PAGE ................................................................................................................... 89
6.9. “PRODUCTION COUNTERS (PALLETS)” PAGE ............................................................................................. 90
6.10. “HMI SETTINGS” PAGE ................................................................................................................................ 91
6.11. “PASSWORD CHANGE” SCREEN ............................................................................................................... 92
6.12. “ENTER PASSWORD” SCREEN (USER LOGIN)” ....................................................................................... 93
6.13. "SERVICE” SCREEN ..................................................................................................................................... 94
6.14. NEW RECIPE PROGRAMMING ................................................................................................................... 95
6.15. PHASE ANGLE ADJUSTMENT .................................................................................................................... 96
6.16. MACHINE SWITCHING ON AND OFF ......................................................................................................... 96
6.17. CYCLE PARAMETERS SETTING ................................................................................................................ 97
6.18. DESCRIPTION OF THE WRAPPING CYCLES ............................................................................................ 97
6.18.1. SINGLE WRAPPING CYCLE ................................................................................................................ 97
6.18.2. DOUBLE WRAPPING CYCLE .............................................................................................................. 97
6.18.3. WRAPPING CYCLE WITH FEEDER .................................................................................................... 98
6.19. CYCLE START AND STOP ........................................................................................................................... 99
6.20. PRESSER HEIGHT CHANGE ....................................................................................................................... 99
6.21. PNEUMATIC CYLINDER WITH ROD ......................................................................................................... 100
6.21.1. MECHANICAL PRESSER ................................................................................................................... 100
6.22. SPOOL LOADING ....................................................................................................................................... 101
6.23. “BUBBLE WRAP” SPOOL LOADING .......................................................................................................... 102
7. MAINTENANCE INFORMATION ..................................................................................................................... 103
7.1. RECOMMENDATIONS FOR MAINTENANCE ................................................................................................ 103
7.2. PERIODICAL MAINTENANCE INTERVALS ................................................................................................... 104
ENG Index 4
7.3. LUBRICATION POINT DIAGRAM ................................................................................................................... 106
7.4. LUBRICANT TABLE......................................................................................................................................... 108
7.5. CONDENSATE DRAINAGE ............................................................................................................................ 109
7.6. AIR FILTER CLEANING .................................................................................................................................. 109
7.7. MACHINE CLEANING ..................................................................................................................................... 110
8. FAULT INFORMATION ................................................................................................................................... 111
8.1. ALARM MESSAGES ........................................................................................................................................ 111
9. REPLACEMENT INFORMATION .................................................................................................................... 112
9.1. RECOMMENDATIONS FOR REPLACING MACHINE PARTS ...................................................................... 112
9.2. REPLACING THE ROTARY TABLE WHEELS ............................................................................................... 113
9.3. REPLACING THE ROTARY TABLE ROLLERS .............................................................................................. 114
9.4. REPLACING THE GUIDING ROLLERS .......................................................................................................... 115
9.5. REPLACING THE ROTARY TABLE GEAR WHEELS .................................................................................... 116
9.6. RECOMMENDED SPARE PARTS LIST ......................................................................................................... 117
9.7. MACHINE DECOMMISSIONING AND SCRAPPING ...................................................................................... 117
9.7.1. MACHINE DECOMMISSIONING ............................................................................................................. 117
9.7.2. MACHINE SCRAPPING ........................................................................................................................... 117
10. ANNEXES ....................................................................................................................................................... 118
10.1. WARRANTY CONDITIONS ......................................................................................................................... 118
10.2. PRESSER PNEUMATIC DIAGRAM ............................................................................................................ 119
10.3. CREASING HEAD PNEUMATIC DIAGRAM ............................................................................................... 120
5 Index ENG
1. GENERAL INFORMATION
1.1. PURPOSE OF THE MANUAL
- The manual is an integral part of the machine and is aimed at providing the operator with the “Instructions for
use” in order to prevent and minimise the risks that arise from human-machine interaction.
The information has been written by the Manufacturer in Italian (the original language) in full compliance with
the professional writing principles and the regulations in force.
The communication principles were chosen according to the target readers in order to ease the reading and
understanding of the information.
The information may be translated into other languages to satisfy the legal and/or market requirements.
The manuals must be translated directly from the original instructions, without modifications.
Each translation (including that provided by the purchasing agent or by the company that introduces the
machine into the country in question) must specify the message “Translation of the original instructions”.
- Refer to the table of contents in order to easily identify the subjects of interest.
- Some information may not correspond completely to the actual configuration of the machine delivered.
- Any additional information does not affect the readability of the text and the safety level.
- The Manufacturer reserves the right to modify the contents of the manual without prior notice provided that the
safety level is not altered.
- Every notification by the recipients can be an important contribution to the improvement of after-sales services
that the manufacturer intends to offer to its customers.
- The symbols described below are used to highlight important information or specifications.
Danger - warning
The symbol indicates critically dangerous situations that if neglected can result in serious personal safety
and health hazards.
Caution - warning
The symbol indicates that suitable actions must be taken in order to avoid personal safety and health
hazards and economic damages.
Important
The symbol indicates particularly important technical and operating information that should not be
neglected.
Maintenance:
The set of operations required to maintain the machine efficient and in good working order.
Normally some operations are scheduled by the manufacturer, who defines the necessary skills and
methods of intervention.
Some unscheduled operations must be performed after consulting the manufacturer.
Operator:
A person chosen and authorised among those who have the requirements, skills and information
necessary for installation, use and ordinary maintenance of the machine.
Maintenance technician:
Technician chosen and authorised among those who have the requirements to perform routine and
extraordinary maintenance on the machine. Therefore, the technician must have accurate information
and competences with particular skills in the field of intervention.
Format changeover:
Set of operations to carry out on the machine before starting to work with characteristics other than
the previous ones.
Training:
Training process aimed at transferring to the new operator the knowledge, skills and behaviours
required to operate the machine autonomously, properly and safely.
Installer:
Technician chosen and authorised by the manufacturer or by its representative, among those with the
requirements to install and test the machine or the relevant system.
Assistant:
Employee assigned to assist the production processes of the machine or system in question.
Production manager:
Qualified technician, with experience and competence in the field of machinery for the reference
sector.
Depending on the production requirements, the production manager can operate the machine directly,
or
select the operator to be assigned to the task.
NO SMOKING
Smoking is not allowed in the area where this sign is located.
NO NAKED FLAMES
This symbol prohibits the use of naked flames near the machine or parts of it to prevent a fire hazard.
NO PEDESTRIANS
Pedestrians are not allowed to pass through the area where this signal is located.
DO NOT PUSH
Caution - warning
Carefully read the “Instructions for use” specified in the manual and those applied directly to the machine.
It is important to dedicate a little time to read the “Instructions for use” in order to minimise the risks and
avoid unpleasant accidents.
Before performing any operation, the operator must make sure that he/she has understood the
“instructions for use”.
Danger - warning
Pay attention to the safety warnings, do not misuse the machine and assess the possible residual risks.
Caution is essential.
Safety is also in the hands of those who interface with the machine throughout its life span.
Important
Sometimes, accidents can be caused by a “careless” use of the machine by the operator.
Usually it is too late to remember what should have been done when the accident has already happened.
Caution - warning
Preserve the readability of the information signs and observe the indications given.
The information signs may have different shapes and colours, indicating hazards, obligations, prohibitions
and indications.
Tampering with the safety devices and the removal of the same may create risks (even severe) for the
operators.
The personnel authorised to carry out any operation with the machine must have acknowledged
experiences in the specific field.
Important
The manufacturer is not responsible for any damage to the packaged product occurred during wrapping,
stabilisation and following operations.
Important
Non-compliance with the instructions given may cause risks to the safety and health of people, as well as
economic damages.
Danger - warning
The personnel authorised to handle the machine (load and unload) must possess the necessary technical
and professional knowledge and skills.
Handle (load and unload) the machine according to the instructions affixed directly to the machine, to the
package and in the user manual.
During handling use one or more assistants, if required. This may pose unexpected risks.
In order to minimise the risks related to assistants’ involvement, you must inform them in advance on the
type of work to be carried out and the behaviour to adopt.
Handling must be carried out with the aid of specific means (crane, forklift truck etc.) by qualified
personnel capable of observing the safety requirements.
When using the lifting means, insert and/or fasten the devices (hooks, forks etc.) only into the points
provided on the package and/or on the machine.
Transport the machine with suitable means of adequate capacity.
The minimum and maximum temperature (during transport and/or storage) must fall within the range
allowed in order to prevent damaging the electrical components.
Install the machine only in spaces with no explosion and/or fire risks.
Avoid spaces exposed to atmospheric and corrosive agents.
Assess, prior to installation, if it is necessary to implement a “safety plan” in order to protect the safety of
the personnel involved.
Provide proper safety conditions when operating in high areas that are dangerous or hard to access.
Install the machine according to the minimum perimeter spaces indicated by the Manufacturer and the
surrounding working activities.
Prepare a machine installation project if the machine is to interact (directly or indirectly) with another
machine or with a production line.
The project must take into account all operating conditions, in order to comply with all laws in force on
matter of safety in the workplace.
Check that the installation space is properly ventilated in order to avoid unhealthy air concentration for the
operators.
Implement the most suitable solutions to minimise noise emission levels and acoustic pollution.
Carry out the electrical connections in accordance with the best practice and in full compliance with the
instructions provided by the Manufacturer and the specific regulations in force.
Important
The electrical connections must be carried out exclusively by operators with acquired and acknowledged
skills in the field of intervention.
The installer must test the machine and check, through a general test, that the machine can be
commissioned without any risk for the operator.
Dispose of all the packaging components in compliance with the standards in force in the Country of
installation.
Non-compliance with the instructions given may cause risks to the safety and health of people, as well as
economic damages.
Caution - warning
Use the machine only with the original safety devices installed by the Manufacturer.
Do not tamper with, disable, remove or bypass the safety devices installed on the machine.
Danger - warning
Do not modify the constructive and functional characteristics of the machine in any way.
Do not use the machine with the safety devices not properly installed and efficient.
Always wear the Personal Protective Equipment indicated in the “Instructions for use”, in particular safety
shoes, and that provided for by the laws in force on matter of safety in the workplace.
Always keep the perimeter areas in suitable conditions and free from obstacles in order to minimise the
risks for the operator, especially near the control station.
The machine must be used by one operator only, that must be appointed and authorised by the employer.
The involvement of one or more assistants when performing some operations or maintenance (ordinary)
interventions may pose unpredictable risks.
In order to minimise the risks related to assistants’ involvement, you must inform them in advance on the
type of work to be carried out and the behaviour to adopt.
Make sure that no unauthorised persons are within the machine operating area during its production
activity and during maintenance.
It is forbidden to climb onto the rotary table with forklift trucks. In addition to being dangerous, it can also
damage the machine.
Important
Non-compliance with the instructions given may cause risks to the safety and health of people, as well as
economic damages.
Risk of slipping:
Do not climb on machine parts during its
operation.
Risk of impact:
Do not approach machine parts during its
operation.
Important
Make sure that the nameplates are clearly legible.
If not, replace and reposition them at the original position.
Rotoplat LP 308-508-708
Rotoplat 308-508-708
- The pallet loading and unloading are performed by the user, who can also insert and cut the film.
- Only one operator is required for its use.
Rotoplat LP 308-508-708
Caution - warning
Risk of crushing upper limbs.
Do not insert the film in the gripper by hand.
Phase 2
Once the cycle has started, the rotary table starts to
turn, while the spool carriage unwinds the film for the
entire height, according to pre-set parameters.
Phase 3
Once the wrapping phase has ended, the machine
stops and film hot cutting and welding are automatically
performed (CW version).
Phase 4
The operator unloads the pallet.
The cycle is complete and the machine is ready to start
a new cycle.
Rotoplat LP 308-508-708
8. Key-operated switch:
it overrides the emergency condition of the spool carriage.
If it is kept turned, it allows to activate the carriage upstroke with the user interface manual controls.
Important
For further details see the wiring diagram.
Rotoplat LP 308-508-708
Important
For further details see the wiring diagram.
Important
For further details see the pneumatic diagram.
Rotoplat 308-508-708
Rotoplat TP3 308-508-708 Rotoplat 308-508-708
Rotoplat LP 308-508-708
Important
During pallet loading/unloading operations it is recommended not to get on the ramps with the
forklift truck.
5. Lifting frame:
Structure which allows lifting the machine from the ground when the floor must be washed or for loading with
electric hand pallet trucks.
Rotoplat 308-508-708
- Template:
Profiled structure for base underground installation.
- Rotary table (ø 1800, ø 2200, ø 2400, ø 1800 “longer”):
it is used to wrap pallets with a size greater than the standard one.
- Brake shaft for mesh (only for “FRD” spool carriages):
it is used to obtain a correct tensioning of the mesh.
- Slide shaft (2400 - 2800 - 3100 mm):
it is used to wrap pallets which are higher than the standard ones.
- Automatic cutting device:
it automatically cuts the film at the end of the cycle.
(Only for machines “Rotoplat - Rotoplat TP3 508-708”).
7. Creasing device:
it is used during wrapping to gather the film in one point, providing the package with a reinforcement point.
Rotoplat 308-508-708
Rotoplat 308-508-708 Rotoplat LP 308FR-508PDS-708PVS
Rotoplat TP3 308-508-708
Rotoplat 308-508-708
Rotoplat TP3 308-508-708
Important
If the Roll-container stop device (3) is used, set the film stretch (4) to low intensity to avoid load
overturning.
Roll-container insertion
Unit of
Description Value
measurement
Film spool dimensions (1)
Max. weight kg 20
Max. weight kg 20
Max. weight kg 12
Description Rotoplat LP
Standard Optional Optional Optional
Shaft height
A 2350 2550 2950 3250
H 2200 2400 2800 3100
B 2532 2732 3132 3432
Load overall 1650 - - -
dimensions
C 1732 - - -
D 2802 - - -
E 1826 - - -
L 1000 - - -
W 1200 - - -
F 3126
Weight (kg) 1200 - - -
Unit of
Description Value
measurement
Film spool dimensions (1)
Max. weight kg 20
Max. weight kg 12
Unit of
Description Value
measurement
Film spool dimensions (1)
Max. weight kg 20
Max. weight kg 20
Caution - warning
Prolonged exposure above 80 dB (A) can be harmful.
The use of appropriate protection systems is recommended (earmuffs, ear plugs, etc.).
Danger - warning
Using this machine in explosive environments or when exposed to atmospheric agents is strictly
forbidden.
Package in crate
Package in cage
Important
For further transportations, recreate the initial packaging conditions for transport and handling.
Important
To handle the TP3 version machine, the brackets must be installed as indicated in the figure.
Rotoplat LP 308-508-708
Danger - warning
Authorised technical service personnel must perform installation and assembly operations.
Proceed as follows:
1. Insert the forklift truck forks in the specially designed spaces provided in the base.
2. Lift the machine from the pallet (if any).
Danger - warning
To perform the operation in safety conditions, insert some wooden blocks under the forks of the forklift
truck and place everything on the floor.
Important
The resting surface must be smooth and well levelled.
Rotoplat 308-508-708
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Rotoplat 308-508-708
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Rotoplat 308-508-708
Rotoplat TP3 308-508-708
3. Connect the lifting device hook in the bracket (M) of the slide shaft and tension.
4. Lift the slide shaft (H).
5. Fasten the slide shaft to the machine body with the screws (N).
6. Tighten the screws of the hinge (L).
Rotoplat 308-508-708
Rotoplat TP3 308-508-708
Rotoplat LP 308-508-708
Rotoplat LP 308-508-708
Rotoplat LP 308-508-708
Important
Store the components for lifting / handling.
C. Insert the supporting knobs (8) and move the upstroke ramp (9).
D. Remove one of the two upper LH (10) or RH (11) guards and one of the two upper connection guards (12) or
(13), by loosening the fastening screws (14).
G. Remove the guard (10) from the initial position and reposition it on the front side, fastening it with the screws
(14).
H. Reposition the photocell receiver connector cable (16) in the guard (10) and in the connection guard (12).
K. Position the upstroke ramp (9) on the side and screw the supporting knobs (8).
L. Recover the cable in excess (16-17) using a tie, connect the connector (6-7) to the photocell receiver and
position the photocell guard (3).
O. Turn the plate clockwise until the reflector (18) is positioned on the opposite side of the loading area.
P. Press the “Home position” button to turn the plate clockwise and position it in the loading point.
Important
The pneumatic connections have already been performed by the Manufacturer if the presser is delivered
with the machine.
Rotoplat 308-508-708
Rotoplat LP 308-508-708
Rotoplat TP3 108-308-508-708
Important
The connections have already been performed by the Manufacturer if the presser is delivered with the
machine.
Rotoplat 308-508-708
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Important
Should it be necessary, insert metal pates (A) between the screws and the floor.
Rotoplat 308-508-708
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Important
The depth (X) must be equal to the machine base height.
Rotoplat 308-508-708
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Rotoplat 308-508-708
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Important
Set the pre-stretch according to the film resistance and quality in order to obtain a low consumption.
Pre-stretch Gear code (L) No. of gear teeth (L) Gear code (N) No. of gear teeth (N)
percentage
150% 2540300068 34 2540300070 85
200% 2540300003 29 2540300002 90
250% 2540300165 25 2540300164 94
300% 2540300027 24 2540300028 95
15. Fit the disc (P) and correctly fasten it to the gear (Q) of the new transmission ratio.
16. Fit the gear (N) of the new transmission gear set.
17. Position the gear with the disc side (P) coupled with the clutch (Q).
18. Fit the retaining ring (M).
19. Fit the gear (L) of the new transmission gear set.
20. Fit the retaining ring (H).
21. Fit the pulley (D).
22. Fit the retaining ring (G).
Important
During reassembly phases, make sure that coupling tabs are correctly
inserted.
23. Rest the plate (F) on the stud bolts, paying attention to fit the belt (C) on the pulley (D).
24. Tighten the screws (E).
25. Tension the belt (C) using the tensioner (B).
26. Manually turn the pre-stretching rollers in both directions to correctly seat the coupling between belt and
pulleys.
27. Check the belt tensioning again and properly adjust it if necessary.
28. Refit the guard (A) when finished.
Rotoplat 308
Rotoplat TP3 308
Rotoplat LP 308
Rotoplat 308-508-708
Danger - warning
Any maintenance operation in this area must be carried out with machine stopped, with electric switch set
to OFF and with no other operator near the machine.
Rotoplat LP 308-508-708
Rotoplat 108-308-508-708
“BUBBLE WRAP”
Caution - warning
Bumper can be triggered by placing an obstacle in front of the machine at a distance of approximately
20 cm.
Important
The frequency of the accidents derived from machine use depends on many factors that cannot always
be foreseen and controlled.
Some accidents may be caused by unpredictable environmental factors, others are mainly due to
users’ behaviours.
On first use, and if required, in addition to being authorised and appropriately informed, the personnel
must simulate some manoeuvres to identify the main controls and functions.
Only carry out the operations foreseen by the Manufacturer and do not tamper with any device to
obtain different performance levels.
Make sure the safety devices are properly installed and efficient before use.
Users, besides complying with these requirements, must apply all the safety regulations and carefully
read the descriptions of the controls and commissioning.
The figure shows the functional logic diagram of the “navigation” modes.
There are two controls for automatic packaging cycle: STANDARD and MULTILEVEL CONTROL (from the “layer
home” page).
MULTILEVEL CONTROL allows breaking down the product height in 5 different levels with adjustable thickness and,
for each one of them, it is possible to adjust film stretch, pre-stretch (only on motorised carriages), reinforcement
wrapping turns, machine rotation speed and carriage speed.
Each one of the 5 levels can be set with values depending on the carriage movement direction, namely also with
different values for upstroke and downstroke.
C) Area:
it displays the preview of the selected pallet wrapping cycle.
D) Button:
it is used to display the “wrapping cycle” page.
E) Button:
it is used to program the number of wrappings in the upper end of the pallet.
The displayed number indicates the programmed value.
F) Button:
it is used to program the number of reinforcing wrappings in the intermediate area of the pallet.
The displayed number indicates the programmed value.
G) Button:
it is used to program the number of wrappings at the base of the pallet.
The displayed number indicates the programmed value.
H) Button:
it is used to program the film stretch value.
The displayed number indicates the programmed value.
L) Button:
it is used to program the film pre-stretch value (only for “PDS” - “PVS” carriages).
The displayed number indicates the programmed value.
M) Button:
it is used to program the speed of the carriage vertical movement.
The displayed number indicates the programmed value.
N) Button:
it is used to program the machine wrapping speed.
The displayed number indicates the programmed value.
O) Button:
it is used to copy the data from one layer to another.
P) Wrapping cycle.
Q) Distance from the ground at wrapping start.
R) Reinforcing wrapping programming.
The list includes the description of the elements (buttons, icons, etc.) displayed in the area.
Button:
it is used to display the “recipes” page.
The displayed number indicates the active recipe.
Area:
it displays the name of the active recipe.
Button (jog):
it is used to move the carriage back to the lower limit
switch.
When the carriage is at the lower limit switch, the button
is not displayed.
Press the “cycle stop” button to stop the movement.
Button:
it is used to display the “manual handling” page.
Button:
it is used to display the “general parameters” page.
Button:
it is used to display the upper level page.
Button:
it is used to display the “home” page.
Button (hold to run) it is used to activate the carriage return and the table synchronisation.
When performing a standard recipe, during the carriage upstroke or downstroke, after having performed the wrapping
at the base of the pallet or at its upper end, it is possible to manually perform intermediate wrapping by pressing the
button (A) with two different modes:
- Keep the button (A) pressed to stop the carriage performing reinforcement wrapping until the button is
released.
- Repeatedly press the button (A) to make the carriage perform as many reinforcement wrapping turns as the
times the button has been pressed (1÷9 turns).
Important
The button is visible only during the machine automatic operation.
Icon (C3): it is used to select the “double wrapping cycle with feeder”.
D) Button: it is used to select the stop modes (automatic or programmed) of spool carriage during
upstroke.
Icon (D1): it is used to select the automatic stop of the spool carriage (upstroke phase)
depending on the height of the pallet being wrapped.
Icon (D2): it is used to select the programmed stop of the spool carriage (upstroke phase)
depending on the height of the pallet.
Enabling this button, (altimeter) will display another button next to button (E) to set the pallet
height.
To obtain a wrapping delay when this function is active, it is necessary to set a height greater
than that of the product to be wrapped.
E) Button: it is used to program the delay of the stopping point of the spool carriage during the
upstroke phase (only with automatic stop).
F) Button: it is used to enable and disable the programming of the distance from the ground
(offset) at the beginning of wrapping.
- Blue background: Function enabled.
- Grey background: Function disabled.
G) Buttons: they are used to program the positioning value and the number of reinforcing
wrappings.
The buttons are visible only if the function has been enabled with the button (F).
H) Button: it is used to enable and disable the reinforcing wrapping programming mode.
- Blue background: Function enabled.
- Grey background: Function disabled.
L) Buttons: they are used to program the positioning value and the number of reinforcing
wrappings.
The buttons are visible only if the function has been enabled with the button (H).
M) Button: it is used to enable and disable the cutting cycle programming mode (Optional).
N) Button: it is used to enable and disable the presser cycle programming mode (Optional).
O) Button: it is used to enable and disable the creasing head cycle programming mode
(Optional).
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Important
To temporarily suspend the cycle, press the “Cycle stop” button (B).
Press the "Cycle Start" button (A) to restart it.
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Caution - warning
For “LP” versions, remove the load after the wrapping cycle
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Presser unit version Slide shaft H (mm) Arm in normal position Arm in normal position H2
H1 (mm) (mm)
2350 2200 1400
2550 2400 1400
Pneumatic cylinder with rod
2950 2800 1400
3250 3100 1400
Rotoplat LP 308-508-708
Rotoplat TP3 308-508-708
Presser unit version Slide shaft H (mm) Arm in normal position Arm in normal position H2
H1 (mm) (mm)
2350 2200 750
2550 2400 750
Mechanical presser
2950 2800 750
3250 3100 750
Important
Unwind the film following the path engraved on the spool carriage plate.
Rotoplat LP 308FR-508PDS-708PVS
Rotoplat TP3 308-508-708
To allow the unwinding of the film on carriages of “PVS” type, it is necessary to press the roller rotation button (C) on
the spool carriage.
Rotoplat LP 708PVS
Rotoplat TP3 708
Danger - warning
Before performing any maintenance operation, activate all safety devices provided and evaluate whether it
is necessary to inform the personnel operating on the machine and the personnel nearby.
In particular, demarcate the neighbouring areas to prevent access to the devices that could, if activated,
cause unexpected hazardous conditions posing a risk for people’s safety and health.
Danger - warning
Maintenance operations must be performed with the machine disconnected from the power and
pneumatic supplies.
The periodical check of the operation of some of the most important parts of the machine, may help to
avoid operation problems and to maintain the machine to the maximum operating levels.
Rotoplat 308-508-708
Lubricant characteristics
Lubricant type Code Parts to be lubricated
Mineral oil 23°C / 50°C - 320 CST 40°C Gear reduction unit
MELLANA OIL 320 IP
SPARTAN EP 320 ESSO
BLASIA 320 AGIP
MOBILGEAR 632 MOBIL
OMALA EP 320 SHELL
ENERGOL GR-XP 320 BP
Mineral oil 32°C / 50°C - 460 CST 40°C Worm screw reduction unit
MELLANA OIL 460 IP
SPARTAN EP 460 ESSO
BLASIA 460 AGIP
MOBILGEAR 634 MOBIL
OMALA EP 460 SHELL
ENERGOL GR-XP 460 BP
Grease TELESIA COMPOUND B IP Gear reduction unit and worm screw
STRUCTOVIS P LIQUID KLUBER reduction unit
TOTALCARTER SYOO TOTAL
Synthetic oil TELESIA OIL IP Gear reduction unit and worm screw
SYNTHESO D 220 EP KLUBER reduction unit
BLASIA S 220 AGIP
Lithium grease ALVANIA R2 SHELL Bearings with support
HL 2 ARAL
ENERGREASE LS2 BP
BEACON 2 ESSO
MOBILIX MOBIL
Synthetic oil -5°C / +5°C VG 68 (SAE 20) Spool carriage lifting chain
+5°C / +25°C VG 100 (SAE 30)
Synthetic oil +25°C / +45°C VG 150 (SAE 40) Table rotation chain
+45°C / +70°C VG 220 (SAE 50)
Important
Do not mix together oils of different brands or having different characteristics.
Rotoplat LP 308FR-508PDS-708PVS
Rotoplat TP3 108-308-508-708
Rotoplat LP 308FR-508PDS-708PVS
Rotoplat TP3 108-308-508-708
Important
For these operations a precise technical expertise or ability is required; therefore, these operations must
be exclusively performed by qualified personnel with certified experience acquired in the specific field of
intervention.
List of alarms
Code Problem Cause Solution
E01 Emergency mushroom-head Emergency mushroom-head Reset the button and press the
button alarm. button pressed “Reset” button
E02 Carriage emergency An obstacle has been detected Remove the obstacle and
along the trajectory during the press the “Reset” button
spool carriage downstroke.
E03 Hand pallet truck emergency An obstacle has been detected Remove the obstacle and
on the pallet loading/unloading press the “Reset” button
ramp.
E04 Protection alarm Intervention of safety barriers or Remove the obstacle and
open door press the “Reset” button
E30 Inverter alarm: POWER DRIVER LOW Contact technical support
1. Table POWER DRIVER HIGH
2. Carriage OVER VOLTAGE
3. Stretch MAX VOLTAGE
4. Pre-stretch UNDER VOLTAGE
5. Presser HW POWER CURRENT
OVER HEAT
PHASE FAIL
CURRENT MAX
CURRENT INT MAX
PARAMETER WRONG
COM.ERROR
E60 “Film breakage” alarm The film has broken or spool is Insert the film or replace spool.
finished
E61 Table synchronisation alarm A fault or an obstacle is Solve the fault or remove the
preventing the table from obstacle and press the “Reset”
moving button
E64 Blocked carriage alarm The carriage has stopped its Remove the obstacle and
travel press the “Reset” button
E65 Blocked presser alarm The presser has stopped its Remove the obstacle and
travel. press the “Reset” button
E71 Presser position alarm Incorrect presser position Move the presser down and
start the cycle
E83 MODBUS alarm. Electronic fault Contact technical support
Important
Before performing any maintenance operation, activate all safety devices provided and evaluate
whether it is necessary to inform the personnel operating on the machine and the personnel nearby.
In particular, demarcate the neighbouring areas to prevent access to the devices that could, if
activated, cause unexpected hazardous conditions posing a risk for people’s safety and health.
When replacing worn parts, use only original spare parts.
The Manufacturer is not responsible for any damage to property or injuries to people caused by the use
of non-genuine spare parts or which may result from repairs not authorised by the Manufacturer.
When ordering new spare parts, follow the instructions given in the spare parts catalogue.
Rotoplat 308-508-708
Rotoplat LP 308-508-708
Danger - warning
Any maintenance operation in this area must be carried out with machine stopped, with electric switch set
to OFF and with no other operator near the machine.
Rotoplat LP 308-508-708
Important
Replace worn parts with original spare parts.
Use oils and greases recommended by the Manufacturer.
All the above will ensure the proper operation of the machine and the correct level of safety.
For purchased components and parts, Robopac S.p.A. offers the user the same warranty conditions that the company
obtains from the suppliers of the aforementioned components and/or parts.
Robopac S.p.A. does not guarantee the conformity of machines to current standards in countries that are not part of
the European Union.
Any adjustment to the regulations in force in the Country in which the machine is installed, will fall under the full
responsibility of the user, who will be responsible also for the changes made, releasing Robopac S.p.A. from any
obligation and/or liability relative to any claim that may be submitted by third parties due to non-compliance with the
referenced standards.